Intelligent Thermal Control for Next-Generation Electric and Hybrid Vehicles

Modern electric and hybrid vehicles demand precise, efficient, and safe thermal management. Our control systems orchestrate the interaction between cabin climate control, powertrain cooling, battery conditioning, and electronics thermal protection – delivering maximum range and passenger comfort in all conditions.

By leveraging waste heat sources, advanced heat-pump strategies, and intelligent control logic, we have achieved up to 37% winter range extension in previous projects. Every solution is built for robustness, safety, and streamlined OEM integration.

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Key Capabilities

Comprehensive Thermal Coverage – Cabin climate, powertrain cooling, battery thermal conditioning, and electronics cooling in a unified control strategy.
Advanced Heat-Pump Optimization – Dynamically prioritizes and blends multiple waste heat sources to minimize energy consumption.
Resilience by Design – Multi-tier sensor, actuator, and mechanical fault handling ensures safe operation under degraded conditions.
Realistic, Extensive Testing – Validation with both real-world driving data and simulated scenarios, including rare and extreme conditions.
OEM-Ready Integration – Proven deployment across multiple platforms with minimal calibration effort.

Development Approach

Thermodynamic system assessment to define physical limits and dynamic behavior
Identification of operating modes, control strategies, and performance targets
Creation of a gray-box model for analysis and early validation

Custom in-house libraries for advanced signal processing
Sensor fault detection and substitution with estimated signals
Handling of known edge cases (e.g., leaving a heated garage)
Actuator non-linearity compensation and resonance damping

Hardware-in-the-loop and gray-box simulations
Repeatable, realistic test sequences including fault injection
Edge-case thermal behavior verification in simulated extreme conditions

Calibration and parameter tuning for specific vehicle platforms
Software packaging for compliance with OEM toolchains and standards
On-site or remote integration support for smooth handover to production teams
Documentation and training for client engineers and maintenance staff

Long-term monitoring of in-field performance
Iterative software updates to adapt to evolving vehicle designs and regulations
Addition of new features and optimizations based on operational data
Rapid issue resolution and support to maintain safety, efficiency, and comfort targets

Overcoming Thermal Management Challenges

Our solutions address the real-world engineering challenges of vehicle thermal systems:

Thermodynamic Uncertainties – No direct two-phase sensors, mode transition complexity, freezing prevention
Environmental Factors – Ice deposition, fog sensitivity, Arctic snow effects, actuator noise
Component Limitations – Low-cost sensor and actuator constraints, network signal degradation
Testing Constraints – Limited natural test conditions, sparse vehicle logging, restricted long-term real-world evaluation